Industrial Minerals & Powder Processing worked example

Screening Loss at 14% maximum acceptable loss target: a worked example

What does the result look like when maximum acceptable loss target reaches 14%? The full calculation is worked below with real intermediate numbers. Use it when a process engineer or quality manager needs to quantify screening losses, track reject rates over time, or justify screen media replacement, classifier tuning, or circuit redesign.

The inputs for this scenario

  • Rejected material (oversize + fines): 9 tons (unchanged)
  • Total feed to screen or classifier: 85 tons (unchanged)
  • Maximum acceptable loss target: 14 % (raised for this scenario; the documented default is 12)

Working through the calculation

  • Applying the documented formula (Screening loss rate = rejected material / total feed to screen x 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 10.59 % for screening loss rate, the number this scenario is built around.
  • At this operating point the engine returns 3.41 pp for gap to loss target.
  • At this operating point the engine returns 9 tons for rejected material.
  • At this operating point the engine returns 85 tons for total feed tonnage.

How this compares with the baseline

  • Against the tool's baseline example, where maximum acceptable loss target sits at 12% and the headline result is 10.59 %, this scenario lands almost exactly on the baseline at 10.59 %.
  • A figure at this level is achievable when maximum acceptable loss target is genuinely sustained, not just peaked for a shift. It treats all rejects equally; it does not distinguish recoverable oversize that can be re-milled from true fines waste, so the headline loss can overstate real material loss.

Results at a glance

  • Screening loss rate: 10.59 % (headline result)
  • Gap to loss target: 3.41 pp
  • Rejected material: 9 tons
  • Total feed tonnage: 85 tons

Run it with your numbers

  • Every input above is editable in the live Screening Loss calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.